Wiring interface

ABSTRACT

A plural level system to achieve simplicity in wiring connections in an electronics bay. The system involves the assigning of wire separation categories for panel connections and incorporates one or more separation dedicated connectors for each category and connects these via integration wire bundles and proper terminals of integration disconnects on the opposite end of the system.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of prior copendingapplication Ser. No. 08/721,415, filed Sep. 26, 1996 which is acontinuation-in-part of application Ser. No. No. 08/392,643, filed Feb.21, 1995, now pending, which is a continuation-in-part of applicationSer. 08/205,907, filed Mar. 2, 1994, abandoned.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to wiring installations and moreparticularly to wiring installations in aircraft electronics bays, maininstrument panels or overhead panels which require extremely complexwiring of multiple systems.

[0004] 2. Description of the Prior Art

[0005] In the patent literature U.S. Pat. No. 4,583,215 to Hargrave, etal. shows a telephone line access system for main distribution framethat employs access blocks comprising sockets and pins for coupling tworows of lightning protectors. One or more integrated circuit modules areattached to each access block and these may be readily affixed to anddisconnected from a main distribution frame.

[0006] U.S. Pat. No. 4,320,261 to Scerbo et al. shows a method foroptimizing cable routing in the distribution panels for an officeenvironment. Means are described for minimizing crossovers and cablelengths. Optimization is based on crossovers and length in contrast tothe present method which considers separation requirements. Also Scerbo,et al. is hardwired in contrast to the present method of usingconnectors.

[0007] U.S. Pat. No. 4,972,298 to Casa et al. is illustrative of highdensity circuit computer assemblies, while U.S. Pat. No. 2,098,321 toTreptow is illustrative of distributing frames in telephone systems.

[0008] U.S. Pat. No. 4,674,819 to Fujitani et al. shows an electric wirebranching device used for forming branching circuits in a wire harness(bundle) system.

[0009] U.S. Pat. No. 5,044,964 to Minerd et al. shows a method ofcontrolling DC devices on a serial data bus by providing a programmableconnector module which eliminates the massive amounts of interconnectivewiring in conventional electromechanical driven systems for controllinga machine.

[0010] The problems of wiring separation, congestion, integration,routing, cross-connected wire bundles, and disconnects in aircraftinstallations have been tolerated and accepted without solution, thetraditional method of complex wiring of multiple systems being to handwire from a connector at the peripheral device to another at e.g., anoverhead panel or directly into the overhead panel. There has been noconsistent system for achieving wire separation, avoiding cross-connectsor minimizing connections or any attempts made to solve the congestionproblem during aircraft final assembly.

BRIEF SUMMARY OF THE INVENTION

[0011] This invention employs a plural-level system to achievesimplicity. Each panel is analyzed to assign wire separation categoriesfor every required connection, then one or more connectors (designatedseparation dedicated connectors) are incorporated for each category. Theopposite end of the system is composed of a set of “integrationdisconnects”. The connections on these are determined by performing awire separation category analysis on the wires coming into theinstrument bay from the peripherals in a given physical area (called adestination area) and assigning at least one connector for eachcategory. The third portion of the system is composed of the“integration wire bundles”. These are designed with breakouts from thebundle body so that they connect the proper terminals of the dedicatedseparation connectors to the proper terminals of the integrationdisconnects. In addition to the above advantages, the present inventionimportantly practically eliminates the need for doing hand wiring atfinal assembly. The features, objects and advantages of the presentinvention will be apparent hereinafter from a detailed description ofthe invention and the appended claims taken in conjunction with theattached drawing of a preferred embodiment.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0012]FIG. 1 is a schematic block diagram of the present basic plurallevel wiring interface;

[0013]FIG. 2A is an exemplary overlay of a present system wiringinterface layout for an overhead panel;

[0014]FIGS. 2B and 2C are taken together on an enlarged view of thesystem of

[0015]FIG. 2A; FIGS. 3A, 3B, 3C and 3D are an exemplary representationof the structure of a typical integration or distribution bundle.

[0016]FIGS. 4A and 4B show examples of Integration Disconnects with andwithout wiring. FIG. 4C shows a typical Integration Disconnect.

[0017]FIG. 4D shows an example of integrating connectors without anIntegration Disconnect bracket.

DETAILED DESCRIPTION OF THE INVENTION

[0018] Initially upon reviewing the aircraft overhead panel orelectronics bay of an aircraft, and due to its inherent wire congestion,complexity, and separation problems, efforts towards a solution of theproblem have generally not been attempted or abandoned. The presentinvention however solves the separation problem by utilizing separationdedicated connectors. Using this method a wire is inserted into theconnector meeting the wire's separation requirement; should multipleconnectors meet the wire's separation requirement, the wire is insertedinto the connector also meeting the wire'gs destination requirements,thereby providing a solution to the separation routing congestion,cross-connected wire bundles, and complexity problems. A wiring matrixresults in simplified discrete integrated wire bundles which areassembled and positioned on the module or overhead panel before finalassembly, thereby completing a module or panel and wiring assembly.Routing integration previously achieved by end point aircraft finalassembly wiring with complex integration wiring panels is eliminated inaccordance with the present plural level wiring interface hereinafterdescribed utilization which is a system utilizing separation dedicatedconnectors, integration disconnects (having no wiring, Ref. FIG. 4A, 4Band 4D), Ref. FIG. 1 and FIG. 2, modular integrated wire bundlebreakouts from the bundle body (Ref. FIG. 1, 3A and 3B). This systempermits wire bundle production on foam boards including connectors andwiring as integral unitary modules.

[0019] Concern has been expressed with regard to the problem ofcross-connected wire bundles at a connector (wiring more than one wirebundle to a single connector). This concern is expressed primarily dueto production, installation and separation problems. Thecross-connection problem is herein solved by the utilization ofseparation dedicated connectors on modules and panels.

[0020] Turning now to FIG. 1, a plural level wiring interface system isshown in which the following symbols are representative of the interfacecomponents:

[0021] MP1, MP2, MP3 are modules or panels

[0022] ID1, ID2, ID3 are integration disconnects

[0023] IB1, IB2, IB3 are integration wire bundles

[0024] DB1, DB2, DB3 are distribution wire bundles

[0025] D1, D2, D3, D4, D5 are destination devices

[0026] E1, E2 are assemblies

[0027] A, B, C, N are dedicated separation categories at connectors 1,2, 3, 4, 5, 6, 7, 8, 9, 10 are connectors

[0028] In the following, the method by which wiring interfaces aredefined and developed will be described:

[0029] As shown in FIG. 1; starting with the most complex module orpanel integration assembly, the separation categories in the module orpanel are determined; A, B, C and N for example, where N is a neutral ornon-critical separation; and for example, Separation A is routed on theleft side, B is routed on the right side, and C is redundant to A and/orB and routed away from A and B. The module or panel is assigned aconnector for each separation category in the module or panel.

[0030] As shown in FIG. 1; MP2 is assigned separation connectors A, B,C; MP3 is assigned separation connectors B and C; and MP1 is assignedseparation connector A/N (since separation category N may be combinedwith any other separation category). The internal wiring of the modulesor panels are separation routed and connected to the separationdedicated connectors (Ref. Definition) of the module or panel interface.Integration wire bundles IB1, IB2, IB3 are used to route wires ofsimilar separation from the module or panel separation dedicatedconnector interface to an integration disconnect ID1 via breakouts fromthe bundle body. Wires from separation dedicated connectors; A of MP2and A/N of MP1 are combined into IB1; B of MP2 and MP3 are combined intoIB2; and C of MP2 and MP3 are combined into IB3. Integration wirebundles IB1, IB2, and IB3 are kept separate from each other and routedto an integration disconnect ID1. (Thus a failure in one bundle will notaffect the wiring in another bundle.) This integration disconnect isclose to or part of the module or panel assembly E1. The integrationdisconnect provides a disconnect for the assembly E1 as well as anintegration interface to the distribution wire bundles. IB1 mates withconnector 1 (separation dedicated A/N) and connector 2 (separationdedicated N); [Note: The integration disconnect connector 2 is used toroute a portion of the separation N wires based on destination, andeliminates the need for wiring at the integration disconnect (Ref.Definition) to enter another distribution wire bundle, (Ref. FIG. 4A, 4Band 4D). IB2 mates directly with DB2 and provides a disconnect functionat connector 3. IB3 mates with connectors 4 and 5 to accommodate thevolume of wires and provide the disconnect function. The distributionwire bundles are used to make long runs with breakouts from the bundlebody (Ref. FIG. 1) to other integration or destination areas. (DB1, DB2,and DB3 are distribution bundles.) DB1 routes separation category Awires direct from ID1 to ID2; (integration disconnect, ID2, is shownbeing used as a production break interface). DB2 routes separationcategory B wires to both ID2 and ID3 (ID3 being shown as an integrationdisconnect interface on an enclosed assembly E2). DB3 accepts separationcategory N wires from IB1 for routing to destination device D5 having asingle C/N separation dedicated connector; DB3 also has routingbreakouts from the bundle body (Ref. FIG. 1) for separation category Cwiring to ID2 and ID3.

[0031] Turning now to FIG. 2A, there is seen a plural level wiringinterface of the kind shown in FIG. 1 however as adapted for an overheadpanel. Only the elements of the present system are shown in heavy lines.

[0032] Referring to FIG. 2A, and enlarged in FIGS. 2B and 2C, givingdetails the following symbols are representative of the interfacecomponents:

[0033] MP1 through MP23 are modules

[0034] ID1A and ID1B are integration disconnects

[0035] IB1 through IB5 are integration wire bundles

[0036] DB1 through DB7 are distribution wire bundles

[0037] E1 is a panel assembly

[0038] A through G are dedicated separation categories at connectors 1through 19 are connectors.

[0039] Separation categories D and E represent (in air/in space/at sea)and (on ground/at port) usage respectively, exclusive usage allows thecombining of these wires into a single connector.

[0040] Separation categories F and G are redundant to categories A andB, and may be combined (provided they have protective shielding from Aand B) to the first distribution breakout.

[0041]FIG. 2A (and 2B and 2C) is a detail of a complex panel, thusdestination devices are not shown.

[0042] Modules MP22 and MP23 interface with both integration anddistribution wire bundles.

[0043] Connectors (1, 2, 3), (4, 5, 6), and (10, 11, 12) are provided tohandle the volume of wires.

[0044] Connectors 8 and 9 on integration disconnect ID1A are provided toseparate and distribute separation category D and E wires.

[0045] Connectors 7 and 13 on integration disconnects ID1A and ID1B areprovided to separate and distribute separation category A and B from Fand G.

[0046] Connectors 1 through 19 also provide a panel disconnect function.

[0047] Referring to FIG. 1, FIG. 2A and FIG. 3B, integration wirebundles route wire of similar separation from various connections ondevices through its bundle body to various connections on other devicesand/or to connections that mate with connections or distribution wirebundles of similar separation. Integration wire bundles are used toroute wire in modules, panels, equipment racks or bays, or otherlocalized areas. An example integration wire bundle structure isrepresented in FIG. 3C. Distribution wire bundles route wire of similarseparation from connections with integration wire bundles to connectionson other integration or distribution wire bundles of similar separationand may route wire directly to devices with connections of similarseparation. Distribution wire bundles are used to route wire betweenintegration areas. An example distribution wire bundle structure isrepresented in FIG. 3D.

[0048] It will be further understood that the plural level wiringinterface arrangements and methods herein described is not limited tothe specific embodiment disclosed by way of illustration, but may assumeother embodiments limited only by the scope of the appended claims.

[0049] Definitions

[0050] Separation Dedicated—Routing necessary for isolation of criticalcircuits to provide safety, dependability and the redundancy to preventhazardous malfunction or simultaneous loss of equipment functions orpropagation of a malfunction or failure.

[0051] Integration Disconnect—Anything that provides a method of matingone or more contacts or connectors with the function or purpose ofproviding integration, combining or distributing, multiple bundleswithout wiring between mating bundle contacts or connectors.

[0052] Bundle Body—the main portion (structure) or collective group ofphysical elements comprising the bundle.

[0053] Breakout—Elements comprising the bundle which exit or enter thebundle body.

1. A plural level wiring interface system for making electrical circuitconnections between a first set of terminals and a last set of terminalscomprising in combination: a plurality of separation dedicatedconnectors coupled to said first and last sets of terminals; a pluralityof integration disconnects coupled to said wiring interface system withintermediate set(s) of terminals; and a plurality of integration anddistribution wire bundles including utilization of wire breakouts from abundle body coupling between said plurality of separation dedicatedconnectors and said plurality of integration disconnects.
 2. A plurallevel wiring interface system according to claim 1 wherein saidintegration disconnects have no internal wiring.
 3. A plural levelwiring interface according to claim 1 wherein the structure of wirebreakouts comprise one or more wires entering or leaving the bundlebody.
 4. A plural level wiring interface system for connecting wirebundles to eliminate wiring integration areas comprising the steps of:providing a plurality of integration wire bundles including wirebreakouts from the bundle body for coupling between a plurality ofseparation dedicated connectors and plurality of integrationdisconnects; and mating a connector plug of one wire bundle directlywith the connector receptacle of another bundle whereby each of saidplurality of integration disconnects have no wiring between theconnectors of mating bundles.